WO2006018008A1

WO2006018008A1 - Energy-saving high-capacity compressor

Info

Publication number: WO2006018008A1
Application number: PCT/DE2005/001407
Authority: WO
Inventors: Thomas Scheb
Original assignee: Patentpool Innovations Management Gmbh
Priority date: 2004-08-19
Filing date: 2005-08-09
Publication date: 2006-02-23
Also published as: DE102004040137A1; DE112005002599A5; EP1789679A1

Abstract

The invention relates to a wobble plate compressor in which lifting pistons are controlled by the wobble plate in an oscillating manner. The lifting pistons (4) oscillate inside the respective cylinders. The cylinder base (3), the cylinder top (2) and the cylinder ring (1) comprise a plurality of valve seats that can be closed via closing elements. The media are alternately supplied via the cylinder base or the cylinder top, and the compressed media are expelled via the cylinder ring.

Description

Energy-saving high performance compressor

Compressors or compressors are used in almost all areas of technology.

There are a variety of systems and types such as turbo compressors,

Screw compressors, reciprocating compressors or high pressure compressors.

Above all, liquid and gaseous fuels are compressed.

Almost all sectors of the manufacturing or processing industries, for example, use compressed air for a wide variety of applications.

Compressed air is an energy form that offers a very wide range of possible applications, combining speed, power, precision and safe handling. The combination of these features make compressed air irreplaceable in many applications. In the upper performance range, with continuously high oil-free compressed air requirements, oil-free screw compressors with frequency control for the peak load and turbocompressors for the base load are often combined into a total solution for large-scale systems.

_^ Of particular interest are the applications for compressed air technology, in which it competes with other forms of energy such as electricity or hydraulics. Compressed air applications have evolved enormously in recent years in terms of efficiency in dealing with primary energy.

The use of compressed air has a variety of applications.

Active air is for example the speech when compressed air is used as a transport medium. Current application examples are the transport of bulk goods, the shuttling of shuttles in weaving machines, use in air storage or the recently rediscovered pneumatic tube.

The example of the air bearing can be beautifully show some advantages of compressed air. Laser cannons for sighting geosatellites, for example, must be precisely aligned and tracked automatically. For the necessary precision of 1/3600 degrees, the optical system is air-bearing. The air bearings allow completely jerk-free and stepless telescopic movements, ensure high measuring accuracy and protect against vibrations. Without compressed air such modern methods of earth surveying would hardly be feasible. If the compressed air is directly integrated into certain processes as process medium, this is referred to as process air. Common areas of application are drying processes, the aeration of clarification tanks or fermentation air for fermentation processes.

Different applications require different pressures. In the rarest cases, it is economically justifiable to compress to the highest required pressure and then reduce the pressure again. It is therefore necessary to categorize the pressure ranges and to use appropriate production systems accordingly.

The range of vacuum and blower applications ranges from the large vacuum up to the overpressure range of about 1 bar. In the area of industrial vacuum, although it is possible to generate this by means of compressed air, the use of special vacuum pumps is here, however, usually more economical.

In the range of 2 to 2.5 bar one speaks of low pressure applications. In most cases rotary positive displacement compressors are used for the production, for extremely large quantities, turbochargers.

For. Standard Pressure - Applications powered by a 7 bar network have a wide range of compressors available. The demands on air volume and air quality determine which compressors work most economically in which combination.

When it comes to the two- and three-digit bar range, oscillating displacement compressors such as piston or diaphragm compressors are used. For large volumes of air, radial turbochargers can also be expected. Every compressed air consumer needs a certain operating pressure in order to deliver the optimum performance. For example, with tools that are powered by only 5 bar instead of the required 6 bar, the load speed already drops by 25%, although the idle speed only decreases by 5%. Therefore, it is essential to check regularly whether the required operating pressure is too available at full capacity. Pressure losses due to insufficient line cross-sections or ^ρ laschen necks can only be noticed when the compressed air also flows. Excessive operating pressures bring no -Leistungsgewinn. They only increase the compressed air consumption and the wear on the devices.

In addition to these aspects of the use of compressed air, the existing energy savings and cost reduction potential is still not well known to many companies.

In Germany alone, the approximately 60,000 installed systems consume electricity with a total value of around 840 million euros every year. This 14 billion kWh of electricity roughly equals the annual electricity consumption of Deutsche Bahn. If the compressed air were generated and used more efficiently, an average of approx. 30% of these energy costs could be saved.

For example, a German sports car manufacturer has already implemented these findings for themselves. By modernizing its compressed air system and consistently implementing optimization measures in the generation, processing, distribution and application of compressed air, it saves 483,000 kWh of electricity a year and thus avoids the emission of around 280 tonnes of CO ₂ .

In addition, there is a desire to improve the existing equipment according to the technical development, for example, in terms of efficiency and reliability.

An essential part of the existing compressors here are the valves used .These should u.a. have the lowest possible flow resistance and the highest possible pressure stability

A specific design principle for such a valve is already known under the number 283656 from the Imperial Patent Office of December 21, 1912. This valve is particularly used for high-speed compressors and consists of balls acting as valve body and is characterized in that the balls are free on their leadership and under the influence of a common resilient plate, which serves as a spring plate for a common load spring (single claim ).

Of the multitude of recent proposals in this field, reference is made here to a valve known from DE 201 02 448 U1, It is a compressor valve with one with a variety of

Valve openings provided valve seat and closing with the valve openings

Closing bodies.

As new and inventive here is referred to, that the closing body are biased by wires, a net or grid against the valve openings and are held in position, the wires, the grid or the grid rest on the closing bodies, but have no fixed connection to these ,

In a further embodiment, it is essentially provided here that the valve openings are chamfered bores and the closing bodies are balls, and that an additional safety net is arranged above the wires, the net or the grid.

This design principle, as can be seen from the patent of the Imperial Patent Office, has long been known and contains in the form disclosed no features that ensure safe and efficient operation. Thus, for example, by the additional safety net no permanent storage of the closing body guaranteed. The arrangement of the valve openings does not meet the fluidic requirements. In addition, the component disclosed herein merely represents the immediate closing mechanism of a valve. The surrounding mechanical support, without which this component is not functional, is not shown.

Likewise, swash plate compressors have been known for a long time. They are among the lowest pulsation and quietest compressors. They are mainly used as air conditioning compressors and compress the gaseous medium so that it (with not too much water) becomes liquid again. In this form, it flows through a condenser and gives off its heat there. The refrigerant is sucked out of the evaporator where it has absorbed the heat of the air flowing into the work space.

Such an air-conditioning compressor usually works on the principle of the axial piston pump.

Distributed uniformly on the circumference in this case several cylinders are arranged, the pistons are moved by a rotating swash plate. In the cylinder head of each cylinder flutter valves are usually arranged, depending on the piston movement the way to the suction -. or release print page. Piston feed pumps work well But to build high pressures have the disadvantage of uneven volume flow.

Therefore, the device according to the invention has for its object to provide a compressor which represents the known concept of said valve construction in conjunction with a swash plate compressor to a powerful new compressor type.

This object is achieved by the devices according to claims 1 and 2, respectively.

The compressor according to the invention is characterized not only by having a novel valve assembly of the type described in the prior art, but also by combining such a valve assembly in a particular manner with a specially designed swash plate type compressor. It should be noted that the mentioned valve assembly is of course not only used in the compressor according to the invention, but that this valve assembly is particularly characterized in that it is very versatile in all devices can be used in which a corresponding valve function is required.

In the valve according to the invention not only a special form of the arrangement of each arranged in a surface valve openings in combination with the associated closing bodies is selected, it is also achieved by a special type of arrangement of the valve openings that, seen in terms of flow, a low flow resistance.

In addition, it is achieved by the particular arrangement of several acting as a valve with valve openings surfaces provided that a, the working medium conveyed, reciprocating piston can act in both directions.

In conjunction with a corresponding transmission, it is possible to have two compressors according to the invention driven by a common drive shaft in a tandem arrangement. The compressor according to the invention will be described in more detail below. They show in detail:

1 shows the valve arrangement according to the invention in an operating position

1a shows the valve arrangement according to the invention in another

operating position

2 shows the valve arrangement according to the invention in a detailed section

3: the detail C of Figure 2

4 is a perspective view of the perforated plate (12)

Fig. 5: a perspective view of the invention

valve assembly

6: a perspective view of the collet chuck (13)

7 shows a sectional drawing of the compressor according to the invention

8 shows a perspective view of this compressor

9 shows a perspective partial view of the grouping of the valves of the compressor according to the invention; FIG. 10 shows a perspective side view of the grouping of FIGS

Valves FIG. 11: a sectional drawing of a tandem arrangement of the compressor according to the invention

In the figure 1, the valve assembly according to the invention is shown in an operating position in which the piston (4), connected to the piston rod (6) rests on the cylinder cover (2). In this case, the entire valve arrangement consists of a cylindrical component which consists of a cylinder ring (1), a so-called cylinder base (3) and a cylinder cover (2). The designations cylinder base (3), cylinder cover (2), or cylinder ring (1) serve only to distinguish the two top surfaces of the cylindrical component, as well as the area-wise curved cylinder jacket. The cylinder bottom (3), the cylinder cover (2), as well as the cylinder ring (1) are substantially constructed so that they consist of arranged in a surface valve openings in conjunction with the associated closing bodies. In the case of the cylinder bottom (3) and the cylinder cover (2), the surfaces are flat, in the case of the cylinder ring, the surface in question corresponding to the cylinder jacket, or the cylinder ring, curved.

In the case of the cylinder cover (2), a surface for receiving the support of the piston rod (6) is recessed in the center receiving the valve openings. This storage has a commercial seal. Preferably, for this purpose, a seal is used, which combines a storage and a seal in a design.

The cylinder ring (1) has an annular area in the middle, which contains no valve openings. The width of this area corresponds to the overall height of the piston (4), which is moved back and forth by the piston rod (6) in the valve arrangement according to the invention.

The sealing of the piston (4) with respect to the inner wall of the cylindrical valve arrangement via a, inserted in a corresponding groove, graphite ring.

In the figure 1a, the valve assembly according to the invention in another operating position of the piston (4) is shown.

Both operating positions show the extreme positions of the piston (4). The running in the middle, free of valve openings, strips in the cylinder ring can be seen in both Figures 1 and Fig. 1a.

The operation of the valve arrangement according to the invention is such that, starting from each of the two described positions or working positions of the piston (4), the operating medium, in the simplest case air, compressed and ejected in the region of the cylinder ring. Each of the direction of movement of the piston opposite cylindrical surface is in this case sealed by the respective closing body.

In this way it is achieved that with each stroke movement of the piston (4) the energy used to compress the working fluid is used. Thus, in the case of FIG. 1, the cylinder bottom (3) is closed by the movement of the piston (4) and the valves in the cylinder cover (2) are opened. In the case of Figure 1a by the following movement of the piston (4) in the opposite set direction the valves of the cylinder cover (2) closed and the valves of the cylinder bottom (3) open and allow the intake air access.

The arrangement of the valves in the corresponding parts of the cylinder ring ensures that the respective areas of the cylinder ring support the desired compression process or suction process. Thus, in the case of Figure 1 by the arrangement of the valves in the cylinder ring (1), which are in the range of the cylinder cover (2) to the middle of the cylinder ring (1) ensures that sucked out of the region of the cylinder cover (2) Air can flow out of the described area of the cylinder ring (1). In the case of FIG. 1 a, it is also ensured that the air drawn in from the region of the cylinder bottom is ensured by the valves in the cylinder ring, which are located in the region of the cylinder bottom (3) up to the middle of the cylinder ring (1) other area of the cylinder ring (1) can flow out.

The detailed sectional drawing of Figure 2 shows the inventive holder of the closing body, or the valve balls used here (9).

A holder of the closing body solely by wires, a net or a grid, as in

Case DE 201 02 448 U1 described, ensures no permanent operation.

The mesh used here, through which the balls against the

Valve openings are pressed so that they only at a corresponding

Pressure of the operating medium, for example, the air, on the valve from the

Solve valve openings can be improved in practice. It has been found that the bearing clearance of the spherical shooting body is too low.

According to the invention it is therefore provided to arrange the valve ball seat (10) set back and the openings of the valve ball seats (10) in each case a steel net (8) to prevent falling out of the valve balls (9).

In the case of the cylinder cover (2) and the cylinder base (3) the steel net (8) is preceded by a perforated plate (12). The relevant detail C is shown separately in Figure (3).

In the figure (3), the position and the configuration of the valve ball seats (10) in detail -dargestellt. As an essential feature to achieve the desired Function is here to emphasize that the angle under which the lower, the ball receiving. Part of a valve ball seat (10) is bevelled at an angle of 118 degrees. This is known to correspond to the angle to be optimally ground under the drill. This drill angle results in an optimum between good chip removal and tool life. It has been found that a valve ball seat (10) designed in this way ensures, after a short operating time, that a valve ball (9) optimally adapts to its respective valve ball seat (10) and virtually creates its own seal by virtue of the harder sphere seen from the material incorporated into the valve ball seat (10). .This ensures a high degree of safety of the seal.

In FIG. 4, a perforated plate (12), as used in the region of the cylinder cover (2) and the cylinder base (3), is shown in a perspective view. As a special feature can be seen here that the diameter of the holes of the holes increase from the middle to the edge. This measure takes into account the fact that at the edge of the valve arrangement according to the invention greater air velocities occur and pass greater amounts of air than in the middle.

FIG. 5 shows the valve arrangement according to the invention from the outside in a perspective view.

^" In the area of the cylinder jacket, the corresponding steel net (11) in conjunction with the outer fabric is clamped on the cylinder ring (1) via a collet chuck (7).

In Figure 6, the collet (7) is shown in a perspective view.

The valve arrangement according to the invention can be used in any system which has the corresponding geometric dimensions and a drive for the piston rod.

It is also possible not to put the piston (4) in an oscillating motion via a piston rod, but rather via a magnetic field which can be oscillated in an oscillating manner outside the valve arrangement according to the invention. The choice of manufacturing materials must be adjusted for this case.

FIG. 7 shows a detailed section through a compressor according to the invention.

Above and below the drive shaft (13) in each case a valve according to the invention can be seen in section. On the used from Figures 1 to 6 reference numerals has been omitted here for reasons of clarity. The drive shaft (13) terminates in an inclined stub shaft (14). This stub shaft (14), by its, with respect to the drive shaft (13), oblique position ensures that the drive pulley (15) in conjunction with the driving ring (16) and the cover plate (17) during the rotation of the drive shaft (13) staggering movement. A cylindrical roller bearing mounted on the stub shaft (14) transmits the inclination of the stub shaft (14) to these adjacent components during a rotation of the drive shaft (13). The securing of these components is achieved by a secured nut or equivalent machine elements. This wobbling movement is transmitted to the respective piston rod (6) by the piston bearing shell (18), the piston bearing ring (19) and the piston bearing back (20), which are embedded in the driving ring (16). These components, which in interaction have the effect of a wobbling disc, force the reciprocating motion of the pistons distributed around the circumference of the compressor.

The corresponding valves are thus also actuated by the movement of the swash plate upon rotation of the drive shaft (13). The actuated piston (4) suck in each movement the corresponding working fluid either on the cylinder cover (2) or the cylinder base (3) and eject it via the cylinder ring (1). The air outlet is designated separately in the figure using the example of the lower valve.

FIG. 8 shows the arrangement shown in section in FIG. 7 in a perspective overall view. In the perspective view shown in Fig. 9, the arrangement of the various disks and rings constituting the swash plate is omitted. There are only the piston bearing shells (18) of the 8 distributed on the circumference valves and associated piston (4), or. Piston rods (6) to recognize.

FIG. 10 shows a perspective view of the compressor according to the invention in a side view. Here, the piston bearing shells (18) are also omitted. Evident are now in the piston bearing shells (18) via the piston bearing rings (19) and the piston bearing backs (20) guided piston rods (6).

FIG. 11 shows a section through a tandem arrangement of a compressor according to the invention.

Here are two compressors, as described above, driven by a common drive shaft. The drive shaft itself learns its drive via an angle gear. In this arrangement, a particularly compact design results.

LIST OF REFERENCES

(1) Cylinder ring

(2) cylinder cover

(3) cylinder bottom

(4) piston

(5) graphite ring

(6) Piston rod

(7) hole ring (collet)

(8) Steel net

(9) Valve ball

(10) Valve ball seat

(11) Steel net

(12) Perforated sheet

(13) Drive shaft

(14) stub shaft

(15) Drive pulley

(16) Driving ring

(17) Cover disc τ 18) Piston bearing shell

(19) Piston bearing ring

(20) Piston bearing back

Claims

claims

Claim 1:

Swash plate type compressor for compressing liquid and / or gaseous media, having the following features:

a), driven by a running in the longitudinal axis of a cylindrical housing drive shaft (13), swash plate actuates the reciprocating piston (4) a plurality of distributed on the circumference of the housing cylindrical valve assemblies, b) the reciprocating piston (4) move oscillating in the respective Valve arrangements, c) the cylinder bottom (3), the cylinder cover (2) and the

Cylinder ring (1) of the valve assemblies comprise a plurality of valve seats (10) which are closable in each case via closing body (9), d) the inflow of the media takes place alternately via the

Cylinder bottom (3) or the cylinder cover (2), wherein the compressed media via the cylinder ring (1) are ejected.

Claim 2:

a) two, driven by a running in the longitudinal axis of a cylindrical housing drive shaft (13), swash plates actuate the reciprocating piston (4) a plurality of distributed on the circumference of the housing cylindrical valve assemblies, wherein the swash plates on the two ends of the drive shaft (13) attached are and the drive (b) the reciprocating pistons (4) oscillate in the respective valve arrangements, c) the cylinder base (3), the cylinder cover (2) and the

Claim 3:

Swash plate compressor according to one of claims 1 or 2, characterized in that the cylindrical valve assemblies have a circular cross-section.

Claim 4:

Swash plate compressor according to one of claims 1 or 2, characterized in that the cylindrical valve arrangements have a cross section which has the shape of a vesica piscis (fish bladder).

Claim 5:

Swash plate compressor according to one of claims 1 or 2, characterized in that the cylindrical valve assemblies have a cross section which has an arbitrary shape Claim 6:

Swash plate compressor according to one of claims 1 to 5, characterized in that the cylindrical valve arrangements have a cross section which is different from each other.

Claim 7:

Swash plate compressor according to one of claims 1 to 6, characterized in that the entire compressor or parts thereof are made of aluminum and / or magnesium and / or carbon.

Claim 8:

Swash plate compressor according to one of claims 1 to 7, characterized in that the valve seats (10) and the closing body (9) are designed so that the closing body (9) in the valve seats (10) have a free movement space.

Claim 9:

Swash plate compressor according to one of claims 1 to 8, characterized in that the closing body (9) in the valve seats (10) via an over-tightened steel net (8), or (12) are secured.

Claim 10:

Swash plate compressor according to one of claims 1 to 9, characterized in that the closing bodies (9) in the valve seats (10) are additionally secured by a perforated plate (12) arranged upstream of the steel net. Claim 11:

Swash plate compressor according to one of claims 1 to 10, characterized in that the perforated plate (12) has bores whose diameter increases from the center of the perforated plate (12) to the outside.

Claim 12:

Swash plate compressor according to one of claims 1 to 11, characterized in that the valve seats (10) are designed as valve ball seats (10) and the closing bodies (9) as valve balls (9).

Claim 13:

Swash plate compressor according to one of claims 1 to 12, characterized in that each valve ball seat (10) at the bottom has a drill angle of 118 degrees.

Claim 14:

Swash plate compressor according to one of claims 1 to 13, characterized in that over the cylinder ring (1) stretched steel net (11) via a collet chuck (7) is fixed.

Claim 15:

Swash plate compressor according to one of claims 1 to 14, characterized in that the lifting piston (4) is moved magnetically.